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All rights reserved / Siemens AG ©
Siemens Automation Concepts
for Paint Shop
Siemens Industry
Competence Center Automotive
V1.2
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 3 18.02.2010
Siemens offers a integrated solution portfolio for paint shops
Press Shop Body Shop Paint Shop Powertrain Assembly
Key challenges:
Non-stop production (6x24h)
Slow and time-intensive
processing
Harsh production environment
(heat, fouling etc.)
High energy consumption
Highest requirements on availability and energy efficiency
Logistics Logistics Logistics Logistics
Automotive
process
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 4 18.02.2010
Process steps and core challenges
Core challenges
in paint shop
Pretreatment E-coating PrimerBase &
Clear Coat
Multi-stage
degreasing and
rinsing
Zinc phosphating,
multiple rinsing with
VE water
Repassivation
process
E-coating
Heating & Cooling
Quality check
Quality check
Sanding
Cleaning (by washing
machine, robot, EMU
system)
Coat Provision
Primer
Heating & Cooling
Sanding
Cleaning
Base coat
Clear coat
Heating & Cooling
Quality check
Underbody Protectionand Sealing
Underbody protection
Seam sealing
Material supply (PVC)
Quality check
Special transportation process of the car body:
Rotations by painting and underbody protection application
Special requirements on Machine Safety:
Fast movements of robots in operation
Clear identification of the car body: Process control depends from car body /skid type
Energy efficient components:High Energy consumption at drying and cooling processes
Innovative visualization concept:
Need for higher flexibility and cost reductions in HMI installation
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 5 18.02.2010
Process steps and core challenges
Technological
answers
Pretreatment E-coating PrimerBase &
Clear Coat
Multi-stage
degreasing and
rinsing
Zinc phosphating,
multiple rinsing with
VE water
Repassivation
process
E-coating
Heating & Cooling
Quality check
Quality check
Sanding
Cleaning (by washing
machine, robot, EMU
system)
Coat Provision
Primer
Heating & Cooling
Sanding
Cleaning
Base coat
Clear coat
Heating & Cooling
Quality check
Underbody Protectionand Sealing
Underbody protection
Seam sealing
Material supply (PVC)
Quality check
Special transportation process of the car body:
Rotations by painting and underbody protection application
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 6 18.02.2010
Optimized communication at E-Coating with wireless technology
Leaky feeder signal transmission
Access
Point
Control box
PLC
Dip basin
E-coating
Rotating car body carrier in dirty environment
Abrasion of the sliding contact surface soils the coat
Chemical vapors cause chemical reactions at the sliding surfaces
Use of contact-free and environment independent wireless
technology for data und energy (up to 1,5kW)
Technological
answers
Client
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 7 18.02.2010
Wired vs. wireless communication solution in paint shop (E-coating, 200m, 20 skids)
WiredInitial Investment Wireless
Client (23 pieces) and communication infrastructure
(Access points, power supply, switches etc.) 24.600 €
Lifecycle cost
Total 39.800 €33.800 €
Total -16.500 €/year
Power rail booster (24 pieces) 17.800 €
Installation costs 40.000 €40.000 €Slip ring (200m) and communication infrastructure 4.000 €
RCOAX infrastructure
(RCOAX cable, connectors, antenna cable, …)3.200 €
-
-
-
-
Installation costs 40.000 €40.000 €Material (power rail booster, …) 1.500 €/year
Maintenance (2 FTEs for 1 day/month) 15.000 €/year
-
-
Installation and commissioning 12.000 € 12.000 €
Technological
answers
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 8 18.02.2010
ROI of wireless solution after 1,5 years
Euro
Break evenCumulated cost savings of wireless
vs. wired solution
ROI calculation of wired vs. wireless communication solution
Discount rate: 20%
Life
cycle
ROI of wireless solution after 1,5 years
Technological
answers
-6.000
7.750
19.208
28.757
36.71443.345
48.87153.476
57.313
60.511
-20.000
0
20.000
40.000
60.000
80.000
100.000
1 2 3 4 5 6 7 8 9 10
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 9 18.02.2010
Optimized communication at underbody protection with wireless technology
Floor conveying technology incl. rotation of the car body simplifies the drop-free
application of underbody protection
Floor conveying technology easier to implement than overhead monorail conveyor
Wireless technology creates user-friendly work environments
Control Unit
PLC PLC
Underbody Protection
and Sealing
PLC
HMI
Access
Point
Technological
answers
HMI HMI
Access
Point
Access
Point
Client Client Client
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 10 18.02.2010
Wireless network configuration with Siemens SCALANCE W
PLC
PROFIBUS
Wireless communication between all kinds of automation
components in different applications
Distributed I/O
IWLAN
Link
…Up to 8 devices
Dual
Access
Point
I/O
Client
RCoax RCoax
Wireless
Mobile Panel
PLC PLC
PC/PG
Client
Access
Point
Rapid Roaming
HMI
Technological
answersPROFINET
Triple
Access
Point
Access
Point
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 11 18.02.2010
Increased flexibility with Siemens wireless technology
Reliable and stable wireless communication Deterministic data exchange in real-time
Redundant wireless networks
Rapid roaming for fast handover of mobile devices
Robust Hardware
Metal enclosure with high degree of protection IP65
Protection against vibration and shock
Extended temperature range (-40°C to +70°C)
Secure access and data transfer
Access control (authentication)
Data encryption
Fast commissioning and reduced maintenance cost
Radio field Planning, Simulation, Engineering, Commissioning, Maintenance & Service
Integrated PROFINET IO diagnostics
Support of PROFIsafe applications
Substitution of dragging leaders and dragging cables
Maintenance free data communication
Client Modules
Antennas
Configuration/Simulation
Access Points
Technological
answers
Reliable
Wireless
Technology
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 12 18.02.2010
Process steps and core challenges
Technological
answers
Pretreatment E-coating PrimerBase &
Clear Coat
Multi-stage
degreasing and
rinsing
Zinc phosphating,
multiple rinsing with
VE water
Repassivation
process
E-coating
Heating & Cooling
Quality check
Quality check
Sanding
Cleaning (by washing
machine, robot, EMU
system)
Coat Provision
Primer
Heating & Cooling
Sanding
Cleaning
Base coat
Clear coat
Heating & Cooling
Quality check
Underbody Protectionand Sealing
Underbody protection
Seam sealing
Material supply (PVC)
Quality check
Special transportation process of the car body:
Rotations by painting and underbody protection application
Special requirements on Machine Safety:
Fast movements of robots in operation
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 13 18.02.2010
Safety technology in paint shops
Base &
Clear Coat
One system for standard and safety results into cost savings
Technological
answers
Personnel protection in area of moving robots during painting
Safety Technology integrated into the automation technology
Securing access to robots for maintenance and cleaning
Safety Technology for definition of secure areas in paint cells
Robot
1
Robot
2
Robot
3
End position
End position
Muting
sensors
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 14 18.02.2010
Siemens offers a comprehensive SAFETY portfolio
Use of Safety PLC and Safety Network
Emergency stop
Safety bus
Standard PLC
StandardI/O
PROFIBUS
Fail-safePLC
Safety relays in separate cabinet
Approx. 20 control relays
Approx. 15 safety relays
Approx. 50 multi-conductor cables,
connectors and plugs
Inter panel wiring
Big cabinets
No safety relays and complex circuits
Less hard wired devices
No inter-panel wiring
Smaller cabinets
Reduction of:
Wired logics
Cabinet size
Time & costs for wiring
Emergency stop
Emergency stop
Fail-safeI/O
Fail-safeI/O
Fail-safeI/O
Emergency stop
Emergency stop
StandardI/O
Standard PLC
Emerg. stop
Safetyrelays
Fail-safeI/O
additional network
additional PLC+Software+Engineering
additional Periphery
Use of Safety PLC and Safety NetworkSafety relays in separate cabinet
Technological
answers
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 15 18.02.2010
Initial Investment Reduction up to 20% by implementing Distributed Safety from Siemens
Use of Safety PLC and Safety Network
Standard & Fail-safe I/O
Fail-safeSIMATIC
PROFINET with PROFIsafe
Standard and SAFETY in one System
Reduction of:
Hardware
Space
Engineering
effort
Components
variety
Programming
Tools
Approx. 20 control relays
Approx. 15 safety relays
Approx. 50 multi-conductor cables,
connectors and plugs
Inter panel wiring
Big cabinets
Elimination of one cabinet incl.
modules
Standard & safety data on one cable
Standard & safety data in one station
Standard & safety program in one PLC
Engineering with one software tool
Less investment average 20%
Emergency stop
Emergency stop
Emergency stop
Emergency stop
Emergency stop
StandardI/O
Standard PLC
Emerg. stop
Safetyrelays
Fail-safeI/O
Technological
answers
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 16 18.02.2010
Investment savings by using PROFIsafe in a typical paint shop robot cell (3 robots) : ~ 20%
Investment w/o
PROFIsafe
Investment w/
PROFIsafe
Reduction of cabinets through elimination of
hardware (cabinet space + control & safety relays)14.000 € 10.000 €
Additional safety modules in distributed operator
panel1.800 € 3.500 €
Reduction of wiring material
(cables, connectors, plugs)3.700 € 2.700 €
Reduction of installation and commissioning costs 12.000 €
(15 days)
9.600 €
(12 days)
Total 31.500 € 25.800 €
Maintenance cost to be neglected
Technological
answers
Investment savings with PROFIsafe: ~ 20 %
Initial Investment
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 17 18.02.2010
Levers for Reduction of Life cycle costsby implementing Distributed Safety from Siemens
Shorter planning and implementation phase
Standardized cabinet design by applying software instead of hard-wired relays
Use of one common engineering and programming tool for standard & safety program
Cost saving by material and warehousing
Less component variety leads to lessspare parts inventory
Increased flexibility in production line
Thanks to program alterations and system add-ons (hard- and software)
Reduced service and maintenance
Fully integrated and system diagnosis
Continuous and consistent operation
Technological
answers
Emergency stop
Fail-safeSIMATIC PLC
Emergency stop
Emergency stop
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 18 18.02.2010
Conventional Safety vs. Safety IntegratedImplementation steps
Conventional Safety Safety Integrated
Modification of the safety logic
within the electrical layoutInstallation of safety I/O modules
Installation of standard input modules
for feedback signals
Modification of the standard
and safety PLC program
Wiring of the safety relays
and feedback signalsCommissioning
Modification of the
standard PLC program
Commissioning
1
Time saving through less
implementation steps
2
3
4
5
1
2
3
Standard & Fail-safeI/O
Fail-safeSIMATIC
PROFINET with PROFIsafe
Emergency stop
Emergency stop
Emergency stop
Faster from design to operation with integrated safety technology
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 19 18.02.2010
Conventional Safety Relays vs. Safety Integrated with PROFIsafe
Before: with safety relays
After: with Safety Integrated
Technological
answers
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 20 18.02.2010
Process steps and core challenges
Technological
answers
Pretreatment E-coating PrimerBase &
Clear Coat
Multi-stage
degreasing and
rinsing
Zinc phosphating,
multiple rinsing with
VE water
Repassivation
process
E-coating
Heating & Cooling
Quality check
Quality check
Sanding
Cleaning (by washing
machine, robot, EMU
system)
Coat Provision
Primer
Heating & Cooling
Sanding
Cleaning
Base coat
Clear coat
Heating & Cooling
Quality check
Underbody Protectionand Sealing
Underbody protection
Seam sealing
Material supply (PVC)
Quality check
Special transportation process of the car body:
Rotations by painting and underbody protection application
Special requirements on Machine Safety:
Fast movements of robots in operation
Innovative visualization concept:
Need for higher flexibility and cost reductions in HMI installation
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 21 18.02.2010
Cost reduction and more flexibility through wireless mobile HMI panel in interim storages
Primer Base Coat
50mPC 477
Thin Client Thin Client
Thin Client
Visualization with conventional mounted HMI panels
Visualization with wireless mobile HMI panels
Primer Base Coat
Technological
answers
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 22 18.02.2010
Mobile Panel 277 wireless with integrated Safety
Features: IP65 housing, max. drop height of 1,2m
7,5” TFT Touch screen, 640 x 480, 64K colours
18 membrane keys with LED
Emergency stop
Key-operated switch
2 x illuminated push buttons
Handweel
Externally accessible USB connection
Configuration with WINCC Flexible 2007
Failsafe Operating and monitoring TÜV / BGIA certified according to SIL 3
HMI authorization for individual operators or places / spots
Identification and distance measurement by transponder technology
Safety function (acknowledge button, emergency-stop) via PROFISAFE
Safety-related operating elements (acknowledge button, emergency-stop)
Increased availability Flexible changing of batteries for continuous operation without interruption
Support of Sm@rt Access und Sm@rt service for flexible plant concepts
SD-/Multi Media Card Combi Slot for fast data transmission
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 23 18.02.2010
Investment savings by using wireless mobile HMI panel: ~ 54%
Technological
answers
Initial Investment
1x PC 477 incl. housing 3.000 €
Total 9.715 €4.475 €
1x Switch X108 (8 port) 340 €
-
-
Mounted HMI panelsWireless mobile
HMI panel
1x wireless mobile HMI 277 IWLAN
1 x access points W788/1Pro
3.300 €
950 €
Cabling for access point (50 m)
1 Switch X005 (5 port)
-
-
3 x Thin Client incl. housing 6.000 €-
Cabling (250 m) 375 €-
75 €
150 €
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 24 18.02.2010
Process steps and core challenges
Technological
answers
Pretreatment E-coating PrimerBase &
Clear Coat
Multi-stage
degreasing and
rinsing
Zinc phosphating,
multiple rinsing with
VE water
Repassivation
process
E-coating
Heating & Cooling
Quality check
Quality check
Sanding
Cleaning (by washing
machine, robot, EMU
system)
Coat Provision
Primer
Heating & Cooling
Sanding
Cleaning
Base coat
Clear coat
Heating & Cooling
Quality check
Underbody Protectionand Sealing
Underbody protection
Seam sealing
Material supply (PVC)
Quality check
Special transportation process of the car body:
Rotations by painting and underbody protection application
Special requirements on Machine Safety:
Fast movements by robots in operation
Clear identification of the car body:
Process control depends from car body /skid type
Innovative visualization concept:
Need for higher flexibility and cost reductions in HMI installation
I IA / HQ / CC A
All rights reserved / Siemens AG ©
Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 25 18.02.2010
Optimized communication at E-Coating
Identification of body type, color etc. for optimized planning and dispatching of orders
Rough environmental conditions (high temperatures, acid, fouling etc.) requires special
product features
Pretreatment
RFID
Interface Interface
PLC
Data storage on mobile data carriers
Heat resistant and dirt resistant data carrier, mounted on car body or on skid
Technological
answers
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 26 18.02.2010
Siemens offers a comprehensive RFID portfolio for paint shops
Comprehensive portfolio for individual
applications and environments:
Heat resistance up to 220°C
Data storage up to 32 Kbyte
Extended write/read distance - up to 0,2m for skid identification
- up to 3m for body identification
For hazardous location use (ATEX)
Protection up to IP68
Highest reliability Fast and high reliable identification (100%)
Reduction of engineering and maintenance costs Fully integrated in SIMATIC portfolio
Standard programming interface
Highest flexibility and scalability Combination of RFID with I/O modules
in distributed periphery systems e.g. ET200pro with up to 6 RFID modules
Easy connectable to PROFBUS and PROFINET
Reader/Communication Interfaces
Moby MDS D139 Moby MDS U589
RF 380T
Moby MDS SLG D 12 S
Technological
answers
High temperature Transponder
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 27 18.02.2010
Process steps and core challenges
Technological
answers
Pretreatment E-coating PrimerBase &
Clear Coat
Multi-stage
degreasing and
rinsing
Zinc phosphating,
multiple rinsing with
VE water
Repassivation
process
E-coating
Heating & Cooling
Quality check
Quality check
Sanding
Cleaning (by
washing machine,
robot, EMU system)
Coat Provision
Primer
Heating & Cooling
Special transportation process of the car body:
Rotations by painting and underbody protection application
Sanding
Cleaning
Base coat
Clear coat
Heating & Cooling
Quality check
Special requirements on Machine Safety:
Fast movements of robots in operation
Underbody
Protection
& Sealing
Underbody protection
Seam sealing
Material supply (PVC)
Quality check
Clear identification of the car body:
Process control depends from car body /skid type
Energy efficient components:
High Energy consumption at drying and cooling processes
Innovative visualization concept:
Need for higher flexibility and cost reductions in HMI installation
I IA / HQ / CC A
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 28 18.02.2010
Paint shop with highest energy consumption in automotive production process
Press Shop Body Shop Paint Shop Powertrain Assembly
Metal forming:
2-9%
20-80 kWh/car
Welding:
9-11%
80-95 kWh/car
Paint systems:
27-50%
230-320 kWh/car
HVAC:
11-20%
95-170 kWh/car
Lighting:
15-16%
130-140 kWh/car
Compressed air:
9-14%
80-120 kWh/car
Materials handling:
7-8%
60-70 kWh/car
Miscellaneous:
4-5%
35-45 kWh/car
Electricity
ConsumptionTotal:
730-1040 kWh/car
* Source: Ernest Orlando Lawrence Berkeley National Laboratory (2003): “Energy Efficiency Improvement and Cost Saving
Opportunities for the Vehicle Assembly Industry”
Production
processTechnological
answers
Due to highest energy consumption in the paint shop
energy efficient components are needed
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Automotive
process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 29 18.02.2010
Example paint shop:Drives for ventilation/exhaust cause high energy consumption
High energy consumption due to:
High need of ventilation and exhaust air in primer
and top coat sub-processes
Slow and time intensive processing require
constant production and energy supply
E-coat oven
Energy efficient
drives
technologies
Technological
answers
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process
Core challenges
in paint shop
Technological
answers
Automation
concept
References
Page 30 18.02.2010
Example paint shop:
Reduced energy consumption through innovative drives
Energy efficient
drives
technologies
Energy-efficient motors from Siemens
with high efficiency (EFF1 class) due to compact
design with up to 40% less power loss compared
to standard motors
SINAMICS frequency converters
Frequency converters capable of energy recovery
with innovative infeed technology where the
braking energy is fed back into the line supply
50
0
Life
cyc
le c
ost
s [%
]
100
0.9
96.8
2.3
0.2
98.7
1.1
0.1
99.0
0.9
12 2015
Purchase price
Installation andmaintenance costs
Energy costs
Motor lifetime in years
1.50 11015 Rated power [kW]
85
70
95
90
75
80
1 10010 PN /kW
highly efficienct motor (EFF1)s
Improved efficency motors (EFF2)
Division into 3 efficiencyclasses acc. to agreementbetween EU and CEMEP
%
N
hstandard motors
Technological
answers
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Core challenges
in paint shop
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answers
Automation
concept
References
Page 31 18.02.2010
Example paint shop:Reduced energy consumption through innovative drives
Plant capacity: max 300.000 cars/year
Plant uptime: 6 x 24 h / 310 days per year
Plant life cycle: 10 years
Motor utilization: 100 %
Energy costs: 0,09 €/kwh
Assumptions
Motors
used for
ventilation
and exhaust air
Motor type (in KW) Amount15 20
18,5 4
22 2
30 (4-pole) 2
30 (6-pole) 7
37 3
45 (4-pole) 3
45 (6-pole) 1
55 22
75 1
90 4
110 8
132 (4-pole) 4
132 (6-pole) 15
160 7
Energy efficient
drives
technologies
Technological
answers
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in paint shop
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answers
Automation
concept
References
Page 32 18.02.2010
Example paint shop:Application of energy efficient motors reduces energy costs
ROI of solution with energy efficient drives after 1,5 years
Total cumulated energy cost savings after 10 years: 0’4 €
Energy efficient drives
(EFF1*) Initial Investment
Standard drives
(EFF2*)
Approx. 100 motors (15 kW - 160 kW)
for ventilation and exhaust air supply320.000 €340.000 €
Energy cost
Price per kWh: 0,09€ 40.000 €40.000 €5.000 Mio €/year
*Energy efficiency class 1, energy efficiency class 2
5.110 Mio €/year
ROI calculation EFF 1 motors vs. EFF 2 motors
Break even
Euro
Life cycle
Discount rate: 20%
-20.000
71.667
148.056
211.713
264.761
308.967
345.806376.505
402.088
423.406
-50.000
50.000
150.000
250.000
350.000
450.000
1 2 3 4 5 6 7 8 9 10
Calculation for a typical paint shop (300.000 cars /year)
Energy efficient
drives
technologies
Technological
answers
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Page 33 18.02.2010
E-coating with rectifiers in paint shops
Rectifier 1
800-1600 A
Rectifier 2
800-1600 A
Rectifier 4
for backup
800-1600 A
DC bus system
Car bodies to be ionized for proper coating of corrosion protection
Coating quality depends on consistency and availability of the ionization process
High direct current (DC) for ionization process generated by large rectifiers
Due to the high energy consumption of the rectifiers
alternative solutions for the ionization process are needed
Anodes 1,…,n
Rectifier 3
800-1600 A
Zone 3
Anodes 1,…,n
E-coating
++++ + + +
-- ------
Technological
answers
Zone 1
+++++++++ +++++++++ +++++++++
--
-
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Page 34 18.02.2010
New rectifier concept with modular anode control for optimized paint processing
Traditional concept with static anode control New concept with modular anode control
Rectifier 1
800-1600 A
Rectifier 2
800-1600 A
Rectifier 3
for backup
800-1600 A
Static electrical field results into
inhomogeneous coating thickness
Limited availability due to central architecture
( Back-up solution necessary)
Body specific dynamic field control
guarantees homogenous coating thickness
Highest availability due to modular architecture
via fieldbus and PLC control
Zone 1 Zone 2Anodes 1,…,n
Technological
answers
+++++ + + + +Anodes 1,…,n Anodes 1,…,n
DC bus system
Network (PROFIBUS)
Loop controlled rectifiers
linked via field bus and PLC
PLC
+++++++++ +++++++++ +++++++
--
+++++++ + +
--
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Core challenges
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Automation
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References
Page 35 18.02.2010
Rectifier solution with SIMOREG DC master improves coating quality and generates energy cost savings
Improved coating quality
Improvement in the coating quality through < 1% ripple
More uniform coating thickness through partial coating of selected areas
Cost savings in coating material and energy
Lower material usage through targeted coating
Energy cost saving: ~ 20 % because of reduction of reactive power
Shorter coating times: ~ 10% because of the homogenous coating process
Efficient network topology
High performance loop control for voltage and current
No back up solution necessary
Technological
answers
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Page 36 18.02.2010
Feedback from GM regarding the Siemens rectifier solution
Technological
answers
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Automation Concepts for Paint shop
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Automation
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Page 38 18.02.2010
Paint ShopTypical Automation Concept for a paint cell
Wired Communication
with Profinet & Profibus
Distributed I/O
with ET200 in IP20 & IP65
Integrated Safety
with PROFIsafe
Plant Visualization
with HMI panels and
WinCC Flexible
Plant control
with SIMATIC PLCs
PC 677 WinCC flexible
ET 200S failsafe
Main control panel
CPU
319F-3PN/DP
Distributed panel
SIMATIC HMI - Push
Button Panel PP17-II
Panels with robot controller
SIMATIC FS400 light curtain
Paint robots
Scalance X208
ET 200S
with
failsafe
motor
starters
and
emergency
stop
ET 200S
with
failsafe
motor
starters
and
emergency
stop
ET 200S
with
failsafe
motor
starters
and
emergency
stop
ET 200S with failsafe
motor starters and
emergency stop
PROFINET
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Automation
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Paint ShopTypical Automation Concept for a conveyor system in paint shops
PC 677 WinCC flexible
ET 200S
ET 200S failsafe
Main control panel
CPU
319F-3PN/DP
Distributed panel
Wireless
Mobile Panel
ET200pro with motor starter
and geared motor
Rail or chain conveyor
IWAN AP 786-2RR
Scalance X208
Monorail overhead conveyor and Lift application
RCoax Antenna Access Point
ClientDrives
Wireless LAN
PROFINET
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Paint ShopTypical Automation Concept for process engineering in paint shops
Ventilator Motor
Sinamics G130
Anodes 1,…,n
+ + + + + + ++
SIMATIC HMI -
Operator Panel
ET 200S wih Siwarex
weighing modul
…
E-Coating
PC 677
WinCC flexible
PC 677
WinCC flexible
PC 677
WinCC flexible
ET 200S with failsafe
motor starters and
emergency stop
CPU
317F-3PN/DP
Painting mix roomBooth and oven
ET 200S
Scalance
X208
Scalance
X208
Scalance
X208
SIMOREG DC-Master
PROFIBUS
CPU
317F-3PN/DP
CPU
317F-3PN/DP
ET 200S with failsafe
motor starters and
emergency stop
ET 200S with failsafe
motor starters and
emergency stop
PROFINET
Control panel Control panel Control panel
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Technological
answers
Increase your Productivity with Siemens
RFID Technology
Safety Integrated
Mobile HMI panels
Industrial Wireless
Energy efficient components
Productivity
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References
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 43 18.02.2010 Autor
Initial Situation
Consistent rating in the top 10 by JD
Power and Associates in spite of
outdated technology
Plant retrofit including a safety
solution and a new plant for the Lexus
RX 330 luxury SUV
Requirements
Increase safety and production
through better diagnostic
Integration of the new safety solution
with the existing controls platform
Reduced downtime
Customer: Toyota, Canada, CambridgeSolution: Future-oriented safety technology and a plant retrofit
Technical Solution
Modernization of the factory through a
retrofit
Installation of top-notch, Control
Reliable safety solution
Space for
milieu photo/
photo of application
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 44 18.02.2010 Autor
Implementation:
Siemens safety solutions that meet EnN954-1
and IEC 61508 standards
Upgrade of "antichip" and "black out" booths
with new Control Reliable safety systems
Using Siemens AS-Interface at Work and the
Simatic S7-300F
Benefits
Higher availability and increased productivity
Implementation with marginal downtime
Reduces hardwiring to nearly zero
Ease of installation
Reduction of commissioning cost and site
time required for retrofit
Ensures enhanced operator safety
Up-to-date safety technology with AS-Interface and Simatic S7-300F
Customer: Toyota, Canada, CambridgeSolution: Future-oriented safety technology and a plant retrofit
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 45 18.02.2010 Autor
Customer: Toyota, Canada, CambridgeSolution: Future-oriented safety technology and a plant retrofit
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 46 18.02.2010 Autor
Initial Situation
Production of around 250,000 VW
Polos p.a.
The plant in Navarra exists since 1984
Renovation and development of the
paint shop
Requirements
Highest levels of environmental
compatibility to be assured
Reliable communication between
central control unit and individual
rotary carriers
Maximum availability to be ensured
Customer: Volkswagen, Navarra, SpainSolution: Optimized communication with Profinet
Technical Solution
Rotational movements that implicate
communication via Wireless LAN
Identification of the bodyshell type by
a tracing system
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 47 18.02.2010 Autor
Implementation:
Simatic S7-416F
Simatic S7-315F onboard carrier control
Sicalis central control system
Communication via Industrial Ethernet
Wireless LAN using leak wave conductors
Scalance Access Points and a switch
Scalance client and an IE/DP link
tracking system Moby I
Benefits
Attrition is avoided as there are no
mechanical links
No conflicts with other IWLAN networks,
mobile telephony and Bluetooth
=> Higher availability
Reduced radiation
Customer: Volkswagen, Navarra, SpainSolution: Optimized communication with Profinet
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 48 18.02.2010 Autor
Customer: Volkswagen, Navarra, SpainSolution: Optimized communication with Profinet
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 49 18.02.2010 Autor
Initial Situation
Originally installed drives reached
their life cycle and synchronization
limits
Stretched and stressed transport
chains led to fractures and many
downtimes
Requirements
Precise synchronization and load
sharing of the conveyor systems
Detection of the stress points
Long life-cycle
Reduction of downtimes
Technical Solution
Innovative drives solution controlling
the speed of every individual drive
→ highest level of synchronization
Space for
milieu photo/
photo of application
Customer: Chrysler, St. Louis, USA Solution: Conveyor technology for a paint shop with Simotion
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 50 18.02.2010 Autor
Implementation
Simotion C motion control system
Operation in sync with the Simotion C230-2 in
combination with Simovert Masterdrives
converters, external encoders and control
software
Two communication networks over Profibus
DP
Touch screen panels Simatic TP270
Benefits
High level of productivity
Extended operation
Control of the speed of every individual drive
powering ach of the conveyor systems
Detection of slightest fluctuations in speed
and chain torque
Control of the positioning and speed of the
individual drives
Communication: Continuous data flow
Real-time images of the entire paint prep
conveyor system
Simotion increases productivity in the paint shop
Customer: Chrysler, St. Louis, USA Solution: Conveyor technology for a paint shop with Simotion
Bereich / Region / Abteilung
Schutzvermerk / Copyright-Vermerk
Seite 51 18.02.2010 Autor
Customer: Chrysler, St. Louis, USA Solution: Conveyor technology for a paint shop with Simotion